Dual-Layer Solid State Battery for High-Voltage MEMS Integration
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Solution Overview
Problem
The limitations of existing battery technologies for Micro-Electro-Mechanical Systems (MEMS) and similar devices include the inability to form integrated batteries with high voltages due to material incompatibilities, requiring multiple single-layer batteries and extensive wiring, which increases size and reduces compactness.
Innovation Solution
The development of dual-layer solid state batteries using substrates with laterally spaced battery cell layers on each surface, allowing physical and electrical contact to create a series arrangement, reducing space and wiring needs, and applicable to various battery chemistries like lithium, zinc, and nickel-metal hydride.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple individually packaged battery cells are connected in series to create high voltage batteries, then the voltage and power are improved, but the device size and complexity increase significantly
Solution Approach 1:
The patent merges multiple battery cells into a single integrated structure by forming cathode and anode electrode layers on opposite sides of a common conductive substrate. This consolidation allows multiple cells to be stacked in series within one compact unit, achieving high voltage without proportionally increasing the device area.
Solution Approach 2:
The patent transitions from a planar arrangement of battery cells to a three-dimensional stacked configuration. By forming cathode and anode layers on opposite sides of a substrate and stacking bipolar sheets vertically, the design utilizes the vertical dimension to increase voltage capacity while maintaining a compact footprint.
2Ease of manufacture
If cathode and anode materials are fabricated on a common conductive substrate to form integrated batteries, then the manufacturing complexity is reduced, but material incompatibility prevents feasible fabrication
Solution Approach 1:
The patent segments the battery structure into distinct cathode and anode regions fabricated on opposite sides of a common conductive substrate. This segmentation allows each electrode type to be optimized independently while maintaining overall integration, resolving the material incompatibility issue by preventing direct contact between conflicting materials during fabrication.
Solution Approach 2:
The conductive substrate serves as an intermediary element that enables the integration of cathode and anode materials without direct interaction. By placing electrode layers on opposite sides of the substrate, the design mediates between incompatible materials, allowing sequential fabrication processes for each electrode type while maintaining electrical connectivity through the substrate.
3Power
If battery cells are laterally spaced apart on a substrate to provide high voltage, then the voltage capacity is improved, but the minimum device size is increased
Solution Approach 1:
The patent resolves the lateral spacing constraint by transitioning to vertical stacking. Instead of arranging battery cells side-by-side on a single substrate plane, the design stacks bipolar sheets vertically with cathode and anode layers on opposite sides, utilizing the vertical dimension to achieve high voltage without increasing the lateral footprint of the device.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the creation of compact, high-voltage integrated batteries for MEMS devices, reducing the size and increasing the capacity and current draw capabilities while maintaining a similar footprint to conventional batteries.
Implementation Method 1
portions of the battery cell layers on the first surface are in physical contact with portions of the battery cell layers on the second surface. The battery cell layers on the first surface and the second surface form a plurality of electrically interconnected battery cells
Data Source
AI summary
Methods for fabrication of electronic systems and systems therefrom are provided. An electronic system includes a first substrate (202) having a first surface (202a) and a second substrate (208) having a second surface (208a) facing the first surface. The system also includes a plurality of battery cell layers (106-112) disposed on a plurality of laterally spaced areas on the first and second surfaces (203, 209). In the system, portions of the battery cell layers on the first surface are in physical contact with portions of the battery cell layers on the second surface and the battery cell layers on the first surface and the second surface form a plurality of electrically interconnected battery cells (206, 212) on the first and the second surfaces that are laterally spaced apart and that define one or more batteries.